# US 2014/0190777 A1 · Brake linings and process of manufacturing thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0190777 A1 - Document ID: US20140190777A1 - Status: Published application - Kind: A1 - Application number: 14/207,488 - Filed: 2014-03-12 - Published: 2014-07-10 - Earliest claimed: 2009-06-19 - Assignees: Duroline S.A. - Applicants: Duroline S.A - Inventors: Jacir DALLEGRAVE - Web page: https://patentgrep.com/patent/US20140190777A1 ## CPC - B29C 43/203: {Making multilayered articles} - B02C 23/08: Separating or sorting of material, associated with crushing or disintegrating (B02C23/18 takes precedence {; beater mills combined with sifting devices B02C13/13, B02C13/14; for tumbling mills B02C17/1835}) - B29C 43/003: {characterised by the choice of material} - F16D 69/00: Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces (clutching elements F16D13/60; braking members F16D65/02) - F16D 69/026: {containing fibres} - F16D 2069/004: {Profiled friction surfaces, e.g. grooves, dimples} - F16D 2069/005: {having a layered structure} - F16D 2200/0069: being characterised by their size - F16D 2200/0086: Moulding materials together by application of heat and pressure - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B02C: CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN ({household tools and machines for pulverising foodstuffs, e.g. coffee and spice mills A47J42/00; pharmaceutical mortars A61J3/02; mechanical processing of refuse and garbage B03B9/06; dressing mould materials by grinding B22C5/04}; obtaining metallic powder by crushing, grinding or milling B22F9/04; {recovery of plastics by disintegrating B29B17/00; crushing raw materials in starch making C08B30/02; beaters for papermaking D21D1/02; crushing devices specially for transport in mines E21F13/002; slag crushing devices F23J1/00; fuel milling devices in combustion apparatus F23K1/00; household devices for crushing coal F24B15/02; ice disintegrating devices F25C5/02}) - F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES ## Abstract The present invention discloses brake lining and process of manufacture thereof using a recycled friction material to form a multilayered brake lining with varying densities. ## Claims ### Claim 1 A method for generating friction material to form a brake lining of a drum brake system, comprising: a recycled friction material; a recycled fresh friction material; and a friction lining materials; wherein: a recycled friction material composition is generated using the recycled friction material, the recycled fresh friction material, and the friction lining materials. ### Claim 2 (depends on 1) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 1, further comprising: pre-forming a predetermined amount of the recycled friction material composition into a pre-form, with a shape of the pre-form having varying quantities of material throughout the pre-form. ### Claim 3 (depends on 1) The method for generating friction material to form brake lining of a drum brake system as set forth in claim 1, further comprising: adding a predetermined amount of fresh friction material composition to the pre-form, and pre-forming the combination of the pre-form and the fresh friction material compositions into a multilayer pre-form, with a shape of the multilayer pre-form having varying quantities of material throughout the multilayer pre-form. ### Claim 4 (depends on 3) The method for generating friction material to form brake lining of a drum brake system as set forth in claim 3, further comprising: hot compression of the multilayer pre-form to induce curing and pressure to produce recycled brake lining, with varying densities having high density regions and low density regions. ### Claim 5 (depends on 3) The method for generating friction material to form brake lining of a drum brake system as set forth in claim 3, wherein: the pre-form includes at least one uneven surface that mates with an inner surface of the added fresh friction material composition, with the inner surface forming a shape that is complementary to the uneven surface to facilitate mechanical resistance against shearing stresses experienced by the multilayer brake lining during braking process. ### Claim 6 (depends on 1) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 1, further comprising: mixing the recycled friction material, the recycled fresh friction material, and the friction lining materials to generates the recycled friction material composition. ### Claim 7 (depends on 6) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 6, wherein: the mixing is performed in one or more stages; with a stage of one or more stages includes mixing for a duration a percentage of a total wt % of the recycled friction material, the recycled fresh friction material, and the compounds of the friction lining material. ### Claim 8 (depends on 7) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 7, wherein: the stage of the one or more stages is comprised of a first, a second, and a third stage. ### Claim 9 (depends on 8) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 8, wherein: the first stage of the one or more stages includes mixing for a first duration: a first percentage of a total wt % of the recycled friction material; a first percentage of a total wt % of the recycled fresh friction material; and a first percentages of a total wt % of the compounds of the friction lining material. ### Claim 10 (depends on 8) The method for generating friction material to form a brake lining of a drum brake system as set forth in claim 8, wherein: the second stage of the one or more stages includes mixing for a second duration: a second percentage of a total wt % of the recycled friction material; a second percentage of a total wt % of the recycled fresh friction material; and a final percentages of a total wt % of the compounds of the friction lining material. ### Claim 11 (depends on 8) The method for generating friction material to form brake a lining of a drum brake system as set forth in claim 8, wherein: the third stage of the one or more stages includes mixing for a third duration: a third percentage of a total wt % of the recycled friction material; and a third percentage of a total wt % of the recycled fresh friction material. ### Claim 12 (depends on 1) The method for generating friction material of a drum brake system as set forth in claim 1, wherein: the recycled friction material is used, uncontaminated friction material from used brake linings used in drum brake systems. ### Claim 13 (depends on 1) The method for generating friction material of a drum brake system as set forth in claim 1, wherein: the recycled fresh friction material is comprised of friction material residue generated at a finishing process of a final brake lining product that is comprised of original, non-recycled, fresh friction material. ### Claim 14 (depends on 1) The method for generating friction material of a drum brake system as set forth in claim 1, wherein: the recycled friction material is prepared by: crushing used, uncontaminated friction material to generate crushed recycled friction material; granulating the crushed recycled friction material to generate recycled friction material particles of a size below a first threshold size; buffering sufficient amounts of the recycled friction material particles for continuous recycling operation; and separating buffered recycled frictional material particles of size below a second threshold size, constituting a finally granulated recycled frictional material particles for use in making brake linings. ### Claim 15 A method for recycling brake linings of a drum brake system, comprising: providing used, uncontaminated friction material, constituting recycled friction material; crushing the recycled friction material to generate crushed recycled friction material; granulating the crushed recycled friction material to generate recycled friction material particles of a size below a first threshold size; separating recycled frictional material particles of size below the first threshold size from particles sizes below a second threshold size; wherein: recycled frictional material particles of size below the second threshold size constitute a finally granulated recycled frictional material particles for use in making brake linings. ### Claim 16 (depends on 15) The method for recycling brake linings of a drum brake system as set forth in claim 15, further, comprising: buffering sufficient amounts of the recycled friction material particles for continuous recycling operation. ### Claim 17 (depends on 15) The method for recycling brake linings of a drum brake system as set forth in claim 15 wherein: the first threshold size of the recycled friction material particles is approximately 8 mm or less. ### Claim 18 (depends on 15) The method for recycling brake linings of a drum brake system as set forth in claim 15, wherein: the second threshold size of recycled friction material particles is approximately 5 mm or less. ### Claim 19 (depends on 15) The method for recycling brake linings of a drum brake system as set forth in claim 15, wherein: the moisture content of the recycled friction material particles is less than or equal to 10% in mass. ### Claim 20 (depends on 15) The method for recycling brake linings of a drum brake system as set forth in claim 15, wherein: the used uncontaminated friction material is obtained by: removing material not part of the friction material; and discarding the friction material that is contaminated. ### Claim 21 A brake lining for a drum brake system, comprising: a first layer that includes recycled frictional material, and is pre-formed to have varying quantities of material throughout the first layer and includes at least one uneven surface; a second layer that includes fresh frictional material that is pre-formed on top of and in combination with the pre-formed first layer to form a dual layer brake lining that has varying quantities of material throughout, with areas having greater quantities of material generating higher density regions of the dual layer brake lining slowing abrasion of lower density regions generated by areas of lesser quantities of materials, with lower density regions of the brake lining improving brake quality; the at least one uneven surface mechanically mates with an inner surface of the second layer of the dual layer brake lining to facilitate mechanical resistance against shearing stresses experienced by the dual layer brake lining during braking process. ### Claim 22 (depends on 21) The brake lining for a drum brake system, as set forth in claim 21, wherein: the recycled frictional material is comprised of used and worn out friction material.